Apparatus for conducting metallurgical process



J 1951 E. R. GILLILAND APPARATUS F OR CONDUCTING METALLURGICAL PROCESS 3 Sheets-Sheet :5

Original Filed July 30, 1948 Patented June 19, 1951 UNITED STATES APPARATUS FOR CONDUCTING METALLURGICAL PROCESS Edwin R. Gilliland, Arlington, Mass., assignor to Standard Oil Development Company, a. corporation of Delaware Original application July 30, 1948, Serial No. 41,667. Divided and this application August so, 1949, Serial No. 113,034

3 Claims. (C1.'2se 24) This application which claims improved ap paratus for reducing metal ores and purifying the reduced metal by smelting is a division of Serial Number 41,667, filed July 30, 1948, wherein the process described herein is claimed.

The present invention relates to apparatus for reducing metal ores and purifying the reduced metal by smelting. More specifically, the invention refers to improved means by which ore reduction and metal smelting may be carried out continuously in a single treating stage using a single integrated metallurgical unit. The invention is particularly applicable to the oxidic ores of those metals which are readily oxidizable at elevated temperatures, such as iron.

In the copending Gilliland application, Serial Number 751,760, filed June 2, 1947, now U. S. Patent 2,526,472, an open hearth furnace type process and apparatus for the smelting of irontype metals are disclosed, in which powdered impure metal is introduced into the molten slag forming the top layer of the furnace charge, to be molten therein, and the heat required for melting the metal is supplied by continuously circulating the slag through a separate heating zone, sufiicient time being allowed for the molten metal to settle out of the slag into the lower molten metal layer before the slag enters the heating zone. As shown in said copending application, this procedure makes possible the melting of powdered impure iron-type metals while at the same time permitting maximum utilization of fuel and control of the carbon content of the metal, independently of the combustion required to supply the necessary heat.

It has now been found that the same principle may be applied to the substantially simultaneous reduction and melting of oxidic ores, in such a.

manner that purified metals such as pig iron or steel may be obtained directly from the oxidic ore in a single integrated unit.

In accordance with the present invention, the oxidic metal ore and the reducing agent are introduced into the molten slag layer of an open hearth-type furnace in such a manner thatthe metal oxide dissolves in the slag and reduction to molten metal takes place in the slag layer. Themolten metal is permitted to settle out of the upper slag layer into the lower molten metal layer. Thereafter the slag is circulated through a heating zone wherein it picks up the heat required for reduction and melting, whereupon the reheated slag is again contacted with the metal ore and reducing agent.

In this manner no separate reduction step is required,'the same fuel may be used for heating and reducing the ore, low" grade ores and reducing agents may be employed, and ore may be converted into finished steel in a single operation.

The ore may be supplied in its natural state 2 or in a partially reduced form. For example, Fe'zOa, F8304 or FeO, or mixtures of these oxides may be used, preferably in a finely divided form. Suitable reducing agents include such conventional reducing bases as hydrogen, carbon monoxide, gaseous or vaporous hydrocarbons, etc., as well as solid or semi-solid materials, such as oil residues, coal, peat, lignite, etc., or coke made from these materials.

When using a reducing gas it may be introduced into the slag either through the under 1 lying layer of molten metal or directly without contacting the molten metal layer. These two methods are substantially equivalent if hydrogen is the reducing gas. However, when a carbonaceous gas, such as CO or a hydrocarbon gas, is used the efiects obtained difier substantially.

Introduction of a carbonaceous reducing gas through the molten metal layer increases the carbon content of the metal by a reaction of the molten metal with the gas. As a rmult, the melting point of the metal is reduced, lower melting temperatures and fuel savings, the reduction of the ore in the slag layer is by the contact of the slag layer with the'carbon. dissolved in the metal layer, and the chemical reactivity of the residual reducing gas remaining after contact with the molten metal is increased. On the other hand, the metal recovered from the molten metal layer is of the type of pig iron rather than of steel.

None of these efiects is obtained when the carbonaceous reducing gas is contacted I r with the slag layer and this method will be more useful whenever any one or more of these effects appear undesirable. In this case, it is preferred to contact the reducing gas with the slag immediately upon the latters return from the hurting zone because the slag temperature is highest at this point and the higher the temperature the higher is the rate of reduction.

The gas remaining after contact with the slag layer and reduction of the metal ore still contains substantial proportions of combustible constituents at a high temperature. In

accordance with a preferred embodiment of the invention, this residual reducing gas may be used to transport the slag, after completion of ore reduction, metabmelting and molten metal settling, from the main treating zone of the furnace to the heating zone to serve therein as a fuel for heat generation, as will appear more clearly hereinafter. Other uses of this residual gas include preheating and/or preliminary partial reduction of the incoming ore, preheating of other solid feed materials, etc.

Solid reducing agents may be introduced directly into the slag layer in the form of powder or lumps. Since these solids are normally l ghter than the slag, special provisions should he made to force the solids through the molten slag as will appear hereinafter. The solid reducing agent need not have a high mechanical strength such as that of "metallurgical coke" because it does not have to support a high burden.

The metal oxide may be added together with the solid reducing agent in the form of suitable mixtures or briquettes, or the metal oxide may be added separately from the solid reducing agent. The first method has the advantage that some reduction may take place even before the ore reaches the slag. However, a careful control of the ratio of oxide to reducing agent is required in this case. If the oxide is in excess,

oxide will be lost with the slag removed from the furnace. If reducing agent is in excess it will build up and slow down the operation. It is preferred, therefore. to combine both methods in such a manner that a small excess of reducing agent is supplied together with the ore in the form of a mixture or briquettes and additional ore is added separately to the slag at a suitable point so as to control the oxide concentration of the slag at a desired level. Additional oxide may also be added to the melting and settling zone intermediate between reducing and heating zones in order to adjust the carbon content of the molten metal.

The gases resulting from the reaction between ore and solid reducing agents may be utilized in substantially the same ways as outlined before in connection with the reacted reducing gases.

- Blagging ingredients such as limestone or the like may be added at various points of the system.

Addition to the heating zone is preferred because the necessary preheat and heat of decomposition may thus be applied directly rather than by slag circulation and the CO: evolved from raw slagging materials may be removed with the flue gass from the heating zone and thus prevented from. consuming valuable reducing agent and heat in the main treating zone of the furnace. When added to the main treating zone, the evolution of CO: will aid in the stirring and mixing of the materials to be treated and/or in a reduction of the carbon content of the molten metal, depending on the exact point of addition. In certain cases these desirable efl'ects may compensate somewhat for the loss of reducing agent and may make this type of addition or a combination ofthis type with addition to the heating section appear attractive.

In accordance with a further embodiment of the invention, fresh ore may be added to the heating zone. In this manner, sensible heat may 'be supplied directly to the ore by a combustion taking place in the heating zone, whereby the amount of heat to be supplied by circulating slag may be substantially reduced.

Further and more specific features and advantages of the invention will appear from the following detailed description of the accompanying drawing in which Figure 1 is a longitudinal horizontal section of a furnace according to the present invention. along the lines BB of Figure 2;

Figure 2 is a longitudinal vertical section of the same furnace along the lines A-A of Figure 1:

Figure3isasectionsimilartothatofFigure z, ofa modified form of furnace according to the invention;

Figure 4 is a longitudinal vertical section of the furnace of Figure 1 along lines CC, illus- Figure 5 is an enlarged longitudinal horizontal section through element 34 of Figure 4; and

Figure 6 is a longitudinal vertical section of the type of Figures 2 and 3, illustrating another modification of the invention.

Before describing the drawing in detail, it may be observed that no attempt is made in the drawing to supply details of constructional features which are common in open hearth furnaces. Wherever possible the construction of the furnace is represented schematically, the purpose being merely to illustrate the features of the present invention. Aside from these features, the furnace may be assumed to be similar to the conventional open hearth furnace.

Referring to Figures 1 and 2, the numerals I, 2, 3, and 4 designate the four walls of the furnace defining the bed 8. Arranged substantially down the middle of the furnace is an upright wall 0 which extends from wall 4 more than half the length of the furnace to a point intermediate the center of the furnace and wall 2, rising from the bed 9 of the furnace preferably to its closed roof 2i and dividing the bed into two sections 1 and I. In the bed a of the furnace at a location close to wall 4, a row of reducing gas inlets I2 is provided which extends over substantially the entire width of section I. A chamber 2! is provided behind wall 4, this chamber being substantially coextensive with the main body of the furnace.

That portion of wall 4 which is in section I is provided with a transverse slot or opening it arranged so as to be in about the mid portion of the slag layer whereby slag continuously runs from the slag layer into the chamber 20. Therefore the liquid level in chamber 29 will normally tend to be substantially the same as or slightly higher than that in section I of the furnace proper. That portion of wall 3 which forms a wall of chamber 29 may be provided with a horizontal row of ports 3i so located as to normally be below the liquid level in chamber 29. These nozzles may be on the same level as, or above or below, the slot 30. That portion of wall 4 which is in section I has a port 82 slightly below the normal liquid level in section I and chamber 2". The end wall ii of chamber 2! is provided with an exhaust flue which leads gases away from chamber 2!.

Closely adjacent wall 4, the roof ii of the furnace is provided with an inlet pipe 22 for powdered ore. Through this pipe additional quantities of slagging constituents, when required, may be introduced together with the ore. Also alloying constituents such as carbon and other metals may be introduced at this point. This pipe near its discharge end may be provided with a cooling jacket (not shown) which may extend through the roof. At a point of roof 2| further removed from wall 4 is an adjustable fine 26 which may serve to draw off gases evolved during the reducing and smelting operation or which may be utilized to feed in inert or reduc ing gases so as to provide a protective blanket over the molten mass.

It will be understood that the furnace is equipped with suitably arranged heating means, which constitute no part of the present invention, for bringing the furnace to reaction temperature. The furnace is charged in the usual manner so as to establish a lower layer 21 of molten metal and an upper layer 28 of slag.

Referring now to Figure 3, the section shown tnting a further modification of Figures 1-8; therein is similar to that of Figure 2 with the exception of the location of the reducing gas feeding means l2, which is now arranged above and in spaced relationship to the bed 9 of the furnace at an elevation determined by a weir 3i extending across the width of zone I of the furnace. The top of weir 34 approximately coincides with the level of the molten metal layerll so that the reducing gas introduced through feeding means 12 passes only through slag layer 28.

Figure 4 is a vertical longitudinal section through zone 8 of the furnace illustrating an embodiment of the invention which may be used in combination with either one of the modifications of zone I illustrated in Figures 2 and 3. Rear wall 4 of the furnace bed is provided in zone 8 with an elongated horizontal slot 30 connecting zone 8 with chamber 29 at such an elevation that the bottom of slot 30 will be within and its top just above the slag layer 23 when the furnace is in operation. A gas feed line 38 arranged in the furnace roof 2i connects slot 30 with a blower or pump (not shown) for the supply of an oxidizing gas such as air. Drawoif lines 38 and to serve the withdrawal of molten metal and excess slag, respectively.

The system illustrated by Figures 1, 2, and 3 may be operated as follows. To start up the furnace it may be charged with metal and slag and heated up to operating temperature so as to form molten metal and slag layers as indicated in the drawing. Line 26 may be closed and a reducing gas be admitted through feeding means l2 in the general manner known in the art of starting .up Bessemer converters. Simultaneously, finely divided ore and any slagging ingredients needed may be charged through line 22 by'any suitable feeding means, such as a standpipe, lockhopper, star feeder, etc. (not shown). The ore is dissolved in slag layer 28 and reduced therein to metal by contact with the reducing gas. The molten reduced metal settles through slag layer 28 into metal layer 21.

As a result of the continuous withdrawal of metal and slag through drawoifs 33 and II) from the end of zone 8, both layers 21. and 28 move continuously in the direction of the arrow.

A portion of the slag is passed through port 39 into chamber 29 wherein it is heated by combustion gases and pumped by applying gas lift principles or the like as described in the copending application identified above. The heated slag in 29 flows through port 32 into section I and supplies the necessary heat for the reactions taking place in sections 1 and 8 of the furnace. The spent reducing gases withdrawn through port 26 may be used as heating gases for section 29 and for this purpose introduced through ports 3|.

Referring now to Figure 4, port 32 is covered by liquid and line 26 is closed, the gas remaining after reduction and still containing substantial portions of combustible constituents is likewise forced in the direction of the arrow and through slot 30 into chamber 29. The velocity of this residual gas may be readily so controlled that a relatively strong flow of at least the upper strata of layer 28 takes place beyond drawoif 3 through channel 33 into chamber 29, as illustrated in greater detail in Figure of the drawing. The relatively narrow cross-section of channel 39 aids in establishing a pumpingaction'of the gas resulting in a strong current of slag from zone 9 into chamber 29. Depending on the gas velocity through, and the design of, port 3., this eifect may be due to gas-liquid friction, sluggingaction, or spraying action, or to a combination of these causes.

Preferably preheated air admitted through pipe 33 is admixed with the gas in channel 39 to form a combustion mixture which burns in channel 39 or chamber 29 and heats the slag therein to the desired temperature. Flue gases are withdrawn through exhaust 20.

It is preferred to maintain in sections I and 8 a pressure substantially higher than that in chamber 29. This may be accomplished either by feeding the, reducing gas at an increasedpressure or by applying suction to exhaust 29, for example by connecting exhaust 2. to a suitable stack (not shown) or by any combination of these means. As a result of this pressure difference, the slag level in chamber 29 is higher than in zones 1 and 8 and the gases flowing through channel 30 bubble through a layer of liquid slag into chamber 29. In order to insure proper circulation of slag from the low pressure chamber 29 into high pressure zone I, port 32 is preferably arranged at a lower level than slot 39, so that the liquid column above port 32 in chamber 29 is higher than that above slot 39. if desired; additional combustion gases, such as suitable mixtures. of gaseous fuel with air, may be introduced through ports 3| into chamber 29 For a better understanding of the embodiment of the invention illustrated in Figures 1-2, reference is made to the following operating details for a typical operation in a furnace of the type described with reference to Figure 4, in which iron ore is simultaneously reduced and melted.

' Example I 1. Daily charge:

A. Iron ore (52% Fe)-46 tons B. Natural gas-4,350,000 cu. ft, (60 F.-

1 atm.)

CH498% N2-2% C. Limestone25.3 tons tion 29) II. Daily production:

Pig iron-22.3 tons Operating temperature-2600 F. Air preheat-1300" F. Operating pressure- Section 29-1 atm. absolute Section 8l6 inches H2O gauge The embodiment shown in Figure 6 is adapted to the use of a solid reducing agent in place of the reducing gas used in'the systems of Figures 1-5. Figure 6, in which apparatus elements similar to those appearing in the preceding figures are identified by the same reference numerals, is a longitudinal vertical section through zone 1; similar to Figures 2 and 3, but modified to suit the special p se of using solid reducing agents.

The construction of the furnace section illustrated by Figure 6 is'substantially the same as that of Figures 2'and 3 with the following excep- (added to sections. Gas feeding means i2 are omitted. A a

bridge wall 42 extends from roof 2! downwardly to a point well within the intended slag layer 23, but above the level of metal layer 21, across the entire width of zone I. Bridge wall 42 is arranged in close proximity to solids feed line 22. A gas passageway 44 penetrates bridge wall 2 in the direction of the longitudinal furnace axis at an elevation closely above the level ofslag layer 23. Line 23 has the form of a solids feed line rather than that of a gas pipe.

- In operation, the furnace may be started up substantially as outlined before. When the proper temperature is reached, ore and solid reducing agent, such as coal, coke, peat, lignite, etc., are

fed through line 22 by suitable feeding means as outlinedbefore. The solids may be fed either separately, or in the form of preformed mixtures or briquettes. Slagging ingredients may likewise be supplied through line 22.

Since the solid reducing agent is normally lighter than the slag it would swim on top of the slag layer and the contact with ore dissolving in the slag would be insuiiicient for an emcient reduction to take place. .This difilculty is overcome by the arrangement of bridge wall 42. The slag and molten metal layers move continuously beneath bridge wall 42 in the direction of the arrow," impelled by metal and excess slag withdrawal through drawofls 38 and 40 and by the pumping action of reaction gases passing through passageways 44 and 30 in the direction of the arrow. However, the solid reducing agent swimming on the slag is held up by bridge wall 42 and allowed to build up to a substantial height of, say. several 'ieet above the slag level. As a result, a considerable portion of reducing agent is forced into the slag whereby proper contact with the dissolved oxides is accomplished. The solid reducing agent may even be forced all ,the way to the bottom of the furnace so that the molten slag and metal oxide filter through'a bed of solid reducing agent whereby excellent contact and reduction are accomplished.

' The gases evolved by the reduction reaction are forced through passageway 44 and pass through reduction zone A should be in closut proximity heating zone and returning it to the furnace bed.

The following operating details will serve to,

further illustrate the embodiment of the invention described with reference to Figure 6.

Example II I. Daily charge:

A. Iron ore (52% Fe)-51 tons B. Coal (non-coking sub-bituminous-75 added through 22, V2 used for producer gas employed in section 29) Total carbon, 55.5 wt. per cent Hydrogen, 6.2 wt. per cent Sulfur, 0.3 wt. per cent Nitrogen, 0.8 wt. per cent Oxygen, 33.9 wt. per cent Ash, 3.3 wt. per cent F xed carbon, 43.1 wt. per cent Volatile matter, 29.3 wt. per cent Moisture, 24.3 wt. per cent- Heating value, 9,400 B. t; u./lb.

(as received basis) C. LimestonF-ZG tons (added to duct 22) 11. Daily production:

Pig iron-25 tons Operating temperature--2700 to 2800 F. Operating pressure-l atmosphere Air preheat-4300' F.

to chamber 2! in order to insure most'eilclent heat utilization and highest reduction rates.-

The gases leaving the reduction zone A may be, wholly or in part, up line 22 countercurrently to the. solids charged in order partially to reduce the ore and to preheat all solids charged through line 22. Particularly in this case, it may be desirable to'feed additional combustion gases through ports 3| as indicated in Figure l. in order to supply the amount of heat and to aid in the proper circulation of the slag. Flue gases from line 2. may be recycled to the system for similar purposes.

Special provisions may be made for the addition of slag and/or metal ore directly to chamber 29. In this manner, the heat required to preheat and decompose theslag and to preheat theore may be applied directly rather than by circulating slag, and the CO: evolved by slag decomposition is kept away from the reducing zone. Substantial savings in reducing agent and fuel requirements may be secured by this modification. Fresh slagging ingredients should be added directly to zone -'I only if this appears desirable for the control of the carbon content of the metal and/or because of the stirring action of the CO: evolved. f

It will be apparent that the apparatus illustrated is amenable to considerable change in detail without suil'ering any change in essential character.- While. the particular embodiments illustrated possess many unique features of construction and arrangement of parts, it is possible to design a suitable apparatus entirely different in appearance and general organim tion from that illustrated while still utilizing the principle of supplying heat to the reducing and smelting operation by circulating slag through a separate Such changes in design and arrangement are contemplated within the scope of the presentinvention.

While the foregoing description and operations have served to illustrate specific applications and results, the invention is not limited thereto- Only such limitations should be imposed on the invention as are indicated in the appended claims.

What is claimed is: V

1. Apparatus for smelting oxidic ores which comprises a reducing chamber, a settling chamber and a heating chamber, said chambers forming interconnected sections in the order mentioned on substantially the same plane of an open hearth type furnace said three chambers being adjacent to each other, a vertical wall common to said reducing and settling chambers and separating the last-named two chambers over the greater portion of their horizontal extension, a second vertical wall perpendicularly arranged to said first-named wail, said perpendicular wall being common to said three chambers and separating substantially removed from said first and second named connections, means for withdrawing molten metal from a lower portion of said settling chamber, means for feeding solids to said reducing chamber, and means for feeding gases to said ing chamber and forming said first-named open connection and wherein said perpendicular wall has a vertical gas passage leading into said port.

EDWIN R. GILLILAND.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 894,383 Imbert July 28, 1908 1,313,274 De Barros Aug. 19, 1919 15 1,940,977 Simpson Dec. 26, 1933 2,426,607 Gronningsaeter Sept. 2, 1947 

